CubeSat – SkeletonSat

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The SkeletonSat is a versatile research satellite, designed to function within the existing CubeSat deployment system. It can be deployed as a single 1U unit or scaled up to 2U, 3U, 6U, and even 12U systems with Stratasys DMLS technology allowing for cost-effective one-part manufacturing. Aluminum AlSi10Mg is used due to its high strength, good thermal properties, corrosion resistance, and excellent machinability. Nylon 12 PA standoffs are utilized in SLS manufacturing for reduced weight while maintaining strength. Equipped with mounting points on all exterior faces (identical patterns on Z and X faces), the SkeletonSat allows modular components to be easily attached using M2 machine screws or drilled out for clearance. Multiple 1U units attach together via machine screws and standoffs, forming 3U systems that can further combine to create a 6U system. This modular design facilitates system expansion and enables easy internal/external component installation using custom 3D printed brackets. The open layout also ensures quick and straightforward wire routing and access between units. The lightweight 1U SkeletonSat weighs merely 115 grams, while a 3U system (including hardware) is only 357 grams - less than 9% of the 4.0 kg limit for a 3U CubeSat. A complete 3U SkeletonSat system requires three units, twelve M2 machine screws, and twelve standoffs.